Asymmetric Semi-Solid Battery for Thick Cathode Energy Density
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Solution Overview
Problem
Conventional battery manufacturing methods result in electrodes with limited thickness, leading to lower capacity, lower energy density, and a high ratio of inactive components, which increases manufacturing complexity and cost.
Innovation Solution
The development of semi-solid cathodes that are thicker than the anode, utilizing a suspension of active and conductive materials in a non-aqueous liquid electrolyte, paired with high energy anodes, allowing for higher active material loading densities and simplified manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional battery manufacturing methods are used with solid electrodes, then manufacturing process is established, but electrode thickness is limited to less than 100 μm resulting in lower energy density
Solution Approach 1:
The patent changes the physical state parameter of the cathode from solid to semi-solid, enabling thickness to increase from less than 100 μm to greater than 100 μm while maintaining manufacturing feasibility. This parameter change resolves the contradiction by allowing thicker electrodes without compromising manufacturing control.
Solution Approach 2:
The patent uses a composite semi-solid cathode structure comprising active material particles suspended in liquid electrolyte, combined with conductive additives. This composite approach enables thicker electrode construction while maintaining electrical conductivity and manufacturability, thereby increasing energy density without sacrificing manufacturing precision.
2Quantity of substance
If electrode thickness is increased to improve capacity, then energy density increases, but the ratio of inactive components to active material increases
Solution Approach 1:
By changing the cathode from solid to semi-solid state, the patent enables increased active material loading density within the electrode volume. This parameter change allows thicker electrodes with higher active material content, improving capacity while reducing the relative proportion of inactive components such as current collectors and separators.
Solution Approach 2:
The patent transitions from two-dimensional thin electrode structures to three-dimensional thicker electrode structures by utilizing the semi-solid cathode formulation. This dimensional change allows significantly increased active material volume while maintaining acceptable ratios of inactive to active components, thereby improving capacity without excessive complexity.
3Quantity of substance
If thicker electrodes are manufactured using conventional methods, then capacity increases, but manufacturing complexity and cost increase
Solution Approach 1:
The patent changes the cathode formulation from solid to semi-solid, which fundamentally alters the manufacturing approach. The semi-solid slurry can be directly cast or injected into the electrode structure, eliminating complex multi-step solid electrode manufacturing processes. This parameter change enables thicker electrodes to be manufactured with reduced complexity and cost.
Solution Approach 2:
The patent extracts the binding and structural formation steps from the manufacturing process by using a semi-solid slurry that self-assembles into the electrode structure during assembly. This extraction of complex manufacturing steps simplifies the overall process, making it easier to produce thicker electrodes without proportionally increasing manufacturing complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach achieves higher volumetric energy densities exceeding 600 Wh/L by reducing inactive components and enhancing the thickness and loading density of electrodes, thereby improving energy density and reducing manufacturing costs.
Implementation Method 1
an ion-permeable membrane disposed between the positive electrode current collector and the negative electrode current collector
Implementation Method 2
A semi-solid cathode that includes a suspension of an active material and a conductive material in a non-aqueous liquid electrolyte
Data Source
AI summary
Embodiments described herein relate generally to devices, systems and methods of producing high energy density batteries having a semi-solid cathode that is thicker than the anode, An electrochemical cell can include a positive electrode current collector, a negative electrode current collector and an ion-permeable membrane disposed between the positive electrode current collector and the negative electrode current collector. The ion-permeable membrane is spaced a first distance from the positive electrode current collector and at least partially defines a positive electroactive zone. The ion-permeable membrane is spaced a second distance from the negative electrode current collector and at least partially defines a negative electroactive zone. The second distance is less than the first distance. A semi-solid cathode that includes a suspension of an active material and a conductive material in a non-aqueous liquid electrolyte is disposed in the positive electroactive zone, and an anode is disposed in the negative electroactive zone.